How to Troubleshoot a PLC System

At this post i will give some basic instructions which are from my personal
experience in order to give you a guide for how troubleshooting in automation
systems (PLC/DCS) is :
Automation systems troubleshooting has in general the same tactic in order to
find the solution of system’s fault.

Nevertheless, depends the complexity and the size of application and the
specific automation system, the troubleshooting steps would be a little different
or more complicated.

The best knowledge is obtained through practice and actual troubleshooting

conditions. Practice again and again is the solution in my opinion. Any
supplement and comments are welcome!!

How to Troubleshoot a PLC System

Before we proceed, we agree that modern automation systems have PLCs for
controlling the application. If we have a small application then the system
possibly has a microPLC (or nanoPLC) or another type of compact controller
(many times this depends of the application).

I said modern automation systems because in the past (before PLCs/other

compact controllers be well known and used by automation development
companies), the control of an automation system was going on only with relays.
Investigate controller’s programme

The first thing we should do, is to find out if we have the right conditions fulfilled
for the operation that is faulty. To do this we should find the “mind” of our
system.

This “mind” is the controller (either this is a kind of PLC or another type of
compact controller). If we don’t have the right conditions fulfilled, then we should
investigate the controller’s programme for finding out the origin of the problem
(ALWAYS check messages appear at SCADA.

This will guide faster to the solution because at SCADA appear important
information such as fault/alarm description or a specific address in PLC).

The thing that we will find out is…

either a faulty signal from hardware (eg a digital signal from a button or a digital
signal from a mechanical switch or a digital signal from a relay’s contact that
“does not come” to controller’s input or an analog signal which has wrong
values) or a faulty signal from another software system (eg SCADA).

Investigate the conditions came from hardware

When we conclude for the origin of the problem, then we leave for a while
controller’s programme and go out to check our conclusions.

We should already have find the drawings of automation system in order to see
the connections for the components we want to check.

For example, if we find out that we have a digital signal from a button which
“does not come” to controller’s input, then we take our multimeter and go to
check the button.
If the button is OK, then we investigate if there is any fuse between button and
controller’s input. If there is, then we check it.

If the fuse is OK, then we investigate the route of the cable. Maybe we have a
cut cable.
If the cable is OK, then maybe we have hardware problem to the controller’s
input and maybe we should change this input module with a new one or
otherwise fix it (the repairs should be done by qualified staff).

Investigate the hardware after the outputs of our controller

If we conclude that we have the right conditions, then we should check the
components that we have between controller and the faulty equipment (we
mean the equipment that doesn’t work as it should).

For example, if we have an industrial furnace that does not close its door (even
though we have the conditions for closing the door from programme), maybe
we have a faulty relay that energizes from PLC (or other controller) for closing
the door.

If the relay is OK, then maybe we have problem with the motor that is
responsible for closing the door. We should check motor for its status (motor
coils, mechanical parts)

If the motor is OK, we should check the voltage values come to motor’s input
(with our multimeter) and also check the cable for its status if multimeter’s
measurements are not right.

If the voltage and cable are OK, then maybe we have a jam somewhere at the
door-furnace construction.

Power units are a “plus”!

Generally, when we have power units (drives) in our automation system in order
to drive a motor, then we should have together the manual of the specific power
unit.

That’s because power units have a digital display or 7-segment led displays or
simple LEd’s for informing us about the fault that exists inside them or at the
driven motor.

This is very useful for engineers and technicians. Also, modern power units
have special algorithms for checking motor status, voltage and current values
etc.

For example, if a motor is overheated, the drive will inform us about it because
it checks continuously the temperature sensor (eg thermistor) which is located
inside motor’s enclosure.

Then we should check the motor if it is overheated actually or we have a faulty

temperature sensor that we should replace it.
Check controllers status

Some times, when the CPU of our PLC detects an unacceptable condition at
the programme’s flow, then it goes to “STOP” mode and possibly a led flashes
and indicates this malfunction.
Also, if any other malfunction is going on to the system, some led’s indicate the
kind of fault (refer to controller’s manual for more information). Same behavior
have in general any kind of controller is established in an automation system.

Safety systems

Many automation systems (often production machines) have in their design

some “safety systems” like “Pilz” or “Siemens Sirius”.

These are smart compact controllers for monitoring situations like protective
door opening or Emergency-Stop. When something of these occurs, the safety
system stops the operation of the automation system for human and machine
protection.

In order to reset the automation system to the functional state, there are special
instructions in safety systems manuals.
The conclusion for all the above is to have a step by step tactic in
troubleshooting. Passing time and getting more experience, maybe we will
bypass some steps, specifically if we are the staff responsible for the
maintenance of a system which we come across every day.

However a good tactic is to be organised and patient. Good luck to your efforts!